Method for stitching vehicle interior components and components formed from the method

ABSTRACT

A method of applying stitching to an interior component is provided herein. The method including the steps of: a) penetrating the outer skin layer, the substrate layer and the intermediary layer with an awl to form a piercing therethrough; b) retracting the awl from the outer skin layer, the substrate layer and the intermediary layer; c) inserting a needle through the piercing through the substrate layer, the intermediary layer and the outer skin layer to grasp a thread positioned on the outer skin layer; d) pulling the thread through the outer skin layer, the intermediary layer and the substrate layer; e) looping the thread with a previous stitch passed through the outer skin layer, the intermediary layer and the substrate layer; f) advancing the interior component to another position, wherein a backside of the substrate layer is free of obstructions; and g) repeating steps a-f until a predetermined amount of stitches are applied to the interior component.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/543,484 filed Jul. 6, 2012, which claims the benefit of U.S.Provisional Application Ser. No. 61/505,833, filed Jul. 8, 2011, thecontents each of which are incorporated herein by reference thereto.

BACKGROUND

This invention relates to an interior structure for a vehicle interior.More particularly, the invention relates to an apparatus for stitchingvehicle interior components.

Currently, most stitching found in an automotive interior is of thefunctional variety, wherein two or more pieces of material (leather,vinyl, TPO, cloth, etc) are cut from a pattern and sewn together(cut-n-sew) prior to being wrapped around a component such as a seatcushion, head rest, arm rest, console lid, instrument panel substrate,etc. Such functional stitching is very labor intensive and is normallyused only where required on low and mid-class vehicles. Functionalstitching on decorate components such as instrument panel retainers anddoor panels has typically been restricted to higher class vehicles dueto cost.

In recent years, automotive original equipment manufacturers (OEMs) haveshown an interest in applying the “stitched” look to more vehicles overa wider range of price classes. A simulated non-functional stitch hasbeen used in some applications; however, the ability to offer asimulated stitch in a contrasting color is not production feasible atthis time. Additionally, more OEMs are requested that a real or “live”stitch be used on decorate components to provide the look and feel of atrue cut-n-sew component.

Accordingly, it is desirable to provide a live, non-functional stitch ondecorative automotive trim components.

SUMMARY OF THE INVENTION

A method of applying stitching to an interior component, comprising anouter skin layer, a substrate layer and an intermediary layer locatedbetween the outer skin layer and the substrate layer is provided. Themethod including the steps of: a) penetrating the outer skin layer, thesubstrate layer and the intermediary layer with an awl to form apiercing therethrough; b) retracting the awl from the outer skin layer,the substrate layer and the intermediary layer; c) inserting a needlethrough the piercing through the substrate layer, the intermediary layerand the outer skin layer to grasp a thread positioned on the outer skinlayer; d) pulling the thread through the outer skin layer, theintermediary layer and the substrate layer; e) looping the thread with aprevious stitch passed through the outer skin layer, the intermediarylayer and the substrate layer; f) advancing the interior component toanother position; and g) repeating steps a-f until a predeterminedamount of stitches are applied to the interior component.

Also provided herein is an interior component of a vehicle formed by theabove method.

In another embodiment, a method of applying stitching to an interiorcomponent is provided. The method including the steps of: a) penetratingthe outer skin layer, the substrate layer and the intermediary layerwith an awl to form a piercing therethrough; b) retracting the awl fromthe outer skin layer, the substrate layer and the intermediary layer; c)inserting a needle through the piercing through the substrate layer, theintermediary layer and the outer skin layer to grasp a thread positionedon the outer skin layer; d) pulling the thread through the outer skinlayer, the intermediary layer and the substrate layer; e) looping thethread with a previous stitch passed through the outer skin layer, theintermediary layer and the substrate layer; f) advancing the interiorcomponent to another position, wherein a backside of the substrate layeris free of obstructions; and g) repeating steps a-f until apredetermined amount of stitches are applied to the interior component.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features, advantages and details appear, by way of example only,in the following description of embodiments, the description referringto the drawings in which:

FIG. 1 is a cross-sectional view of an interior portion of a componentstitched in accordance with an exemplary embodiment of the presentinvention; and

FIG. 2 is a flow chart illustrating a method according to one exemplaryembodiment of the present invention.

DETAILED DESCRIPTION

Turning now to the drawings, wherein to the extent possible likereference numerals are utilized to designate like components throughoutthe various views, in FIG. 1 it is seen that an interior portion 16 of avehicle is illustrated. In one implementation interior portion 16 is aportion of an instrument panel of a vehicle.

As best illustrated in FIG. 1, the interior portion 16 is preferably ofa multi-layered construction. This multi-layered construction preferablyincludes an outer skin layer 18 having a substantially smooth outersurface and an underside facing away from the outer surface. The outerskin layer 18 is preferably formed of a plastic material of substantialflexibility and aesthetically pleasing character.

In order to enhance the softness of portion 16, a layer of cushioningsupport material 20 is provided in the region below the outer skin layer18. It is contemplated that the cushioning support material 20 may be ofany number of different constructions although a foamed material such ascross linked polypropylene (XLPP) foam may be potentially preferred. Asubstrate panel 22 of dimensionally stable plastic or other suitablematerial is preferably disposed below the cushioning support material.

According to the potentially preferred embodiment, the cushioningsupport material 20 and the substrate panel 22 thus serve cooperativelyto provide a support structure for the outer skin layer 18.

It is contemplated that XLPP foam forming the cushioning supportmaterial 20 may be blown between the outer skin layer 18 and thesubstrate panel 22 so as to form a multi-layered composite structure ofa form substantially as illustrated in FIG. 1. It is also contemplatedthat the cushioning material 20 may be attached to the outer skin layer18 in a preliminary cladding operation so as to form a preliminarylayered composite which may thereafter be applied across any substratepanel 22 as may be utilized.

In accordance with an exemplary embodiment of the present invention livenon-functional stitching can be applied interior portion in one of thefollowing ways:

1) Stitch a pattern on an unformed single or multilayer construction oftrim material and wrap the sewn trim sheet around a preformed/precutsubstrate;

2) Stitch a pattern on a preformed single or multilayer construction oftrim material and bond the sewn trim preform to a preformed moldedsubstrate; and

3) Stitch a pattern on a flat or relatively flat single or multilayertrim & substrate component construction.

As the part complexity and size increase, option 1 becomes impracticalas unformed trim material can only be applied to relatively flatsurfaces.

Option 2 requires that the size and shape of the preformed & stitchedskin match that of the molded substrate nearly perfect. Also, option 2requires that all surfaces in die draw have adequate draft in order toaccommodate nesting without damage to the preform. All undercuts withOption 2 require automated or manual edge wrapping to finish.

Option 3 eliminates the fit and finish issues associated with option 2but is limited by the ability of the sewing machine to reach confinedareas of the part while possessing the capability to drive a needlethrough trim and substrate material of the component. Likewise, anybackside features (ribbing, bosses, etc.) required for componentstructure or attachment cannot be located in the area directlybehind/beneath the stitch path.

This application proposes a means to stitch through trim and substrateof a large, contoured soft trim clad automotive interior trim panel toeliminate the manufacturing cost and complexity associated with Option 2above and be designed and manufactured in such a way that the stitchingcan be located directly above backside features if required.

Various exemplary embodiments of the invention described herein consistsof the use of a chain stitch pattern machine that uses an awl on theupper portion of the head to penetrate the trim and substrate of theinterior component. After the awl exits a hole 24 it produced in thecomponent, a needle with a hook protrudes into and through the hole 24from the lower arm of the machine to grasp the thread held in positionby a thread tensioner arm. Once hooked, the thread is pulled through thehole and through the loop from the previous stitch. The needle alsoadvances the part to the next point of awl penetration as it pulls thethread down through the hole 24. The needle then advances to the hookposition once again while the awl is engaged with the part so the partdoes not move and needle can move through the newly formed hole withouthesitation once the awl exits the part.

By utilizing an awl to produce the stitch hole, much more robustmaterial constructions can be stitched (composites, metals, etc) withminimal damage to the top surface of the part or the awl. Damage to thethread is minimized by the fact that the thread is not pulled back andforth through the hole multiple times as is the case with the lockstitchpattern. Very large tex threads can be used without concern for needlebreakage.

The post bed stitch plate for such a chain stitch machine as describedabove can be a small as 10 mm×15 mm, a significant reduction fromprevious robotic chain stitch plate dimension of 16 mm×44 mm (of course,dimensions greater or less than these are considered to be within thescope of exemplary embodiments of the present invention). Access to verytight confines of parts is now possible, particularly through-planeradii wherein minimizing stitch plate length is critical.

The optimal machine configuration for sewing trim/substrateconstructions in a manual fashion would be a high post, long armmachine. Manual or fixture guided part feed would be required.

The optimal machine configuration for robotic sewing would be dependenton the part design. The key factor again is the compact size to thestitch plate. Cylinder arm length and post bed height would depend onthe application.

To facilitate the stitch location on the part, it is proposed that thebackside or ISM side of the retainer be free and clear of any multiplanestyle line, ribs, bosses or any other obstruction that would preventpassage/contact of the stitch plate along the backside of the part forthe entire stitch length. In the event that a backside feature cannot bemoved from the stitch path, it is proposed that a separate component bemolded which contains said feature and be subsequently attached thesubstrate after stitching. This secondary attachment could be performedvia heat staking, IR welding, adhesives, or any other suitable method.

It is also proposed that the substrate material be locally reduced to athickness more suitable for stitching should the need arise. Forinstance, a part with a nominal wall thickness of 2.5 mm could locallybe reduced to 1.5 or 2.0 mm at a width of 15 to 20 mm along the stitchpath. This depression in the backside of the part would also serve tolocate a separate piece containing ribs or bosses as needed prior toattachment. Compression molding of the substrate panel could accommodatea reduction in nominal wall thickness from 2.0 mm to 1-1.5 mm in thestitching area. Of course, dimensions greater or less than theaforementioned values are considered to be within the scope of exemplaryembodiments of the present invention.

Referring now to FIG. 2 a flow chart 30 illustrating a method ofapplying stitching to an interior component according to one exemplaryembodiment of the present invention is provided. Here the interiorcomponent has an outer skin layer, a substrate layer and an intermediarylayer located between the outer skin layer and the substrate layer.

At box 32, the outer skin layer, the substrate layer and theintermediary layer are penetrated with an awl to form a piercingtherethrough. At box 34, the awl is retracted after the piercing isformed.

Thereafter and at box 36, a needle is inserted through the piercing(e.g., through the substrate layer, the intermediary layer and the outerskin layer) to grasp a thread positioned on the outer skin layer. Oncethe step of box 36 is completed, the thread is pulled through the outerskin layer, the intermediary layer and the substrate layer at box 38.

Afterwards and at box 40, the thread is looped with a previous stitchpassed through the outer skin layer, the intermediary layer and thesubstrate layer, unless of course this is the first stitch. Once thestep of box 40 is completed, the interior component is advanced or movedto another position relative to the awl and needle at box 42 and thenthe processes or steps of boxes 32-42 are repeated until a predeterminedamount of stitches are applied to the interior component.

While the invention has been described with reference to an exemplaryembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the presentapplication.

What is claimed is:
 1. A method of applying stitching to an interiorcomponent, comprising an outer skin layer, a substrate layer and anintermediary layer located between the outer skin layer and thesubstrate layer, the method comprising: a) penetrating the outer skinlayer, the substrate layer and the intermediary layer downwardly with anawl to form a piercing therethrough; b) retracting the awl upwardly fromthe outer skin layer, the substrate layer and the intermediary layer; c)inserting a needle upwardly through the piercing through the substratelayer, the intermediary layer and the outer skin layer to grasp a threadpositioned on the outer skin layer; d) pulling the thread downwardlythrough the outer skin layer, the intermediary layer and the substratelayer; e) looping the thread with a previous stitch passed through theouter skin layer, the intermediary layer and the substrate layer; f)advancing the interior component to another position, wherein a backsideof the substrate layer is free of obstructions; and g) repeating stepsa-f until a predetermined amount of stitches are applied to the interiorcomponent.
 2. The method as in claim 1, wherein outer skin layer, isformed from the group consisting of vinyl, leather and thermoplasticpolyolefin; and the intermediary layer is a foam and the substrate layeris formed from plastic.
 3. An interior component formed by the method ofclaim 2, wherein the interior component is an interior trim piece of avehicle.
 4. The interior component of claim 3, wherein the interior trimpiece is a portion of an instrument panel of the vehicle.
 5. An interiorcomponent formed by the method of claim 1, wherein the interiorcomponent is an interior trim piece of a vehicle.
 6. The interiorcomponent of claim 5, wherein the interior trim piece is a portion of aninstrument panel of the vehicle.
 7. The method as in claim 1, whereinouter skin layer, is formed from leather and the intermediary layer isfoam and the substrate layer is formed from plastic.
 8. The interiorcomponent formed by the method of claim 1, wherein the backside of thesubstrate layer is free of obstructions along the entire stitch length.9. The interior of claim 8, wherein the interior component is aninterior trim piece of a vehicle.
 10. The interior component of claim 9,wherein the interior trim piece is a portion of an instrument panel ofthe vehicle.
 11. The interior component formed by the method of claim 1,wherein the backside of the substrate layer is configured to have aseparate component attached thereto, the separate component being freeof any obstructions.
 12. The interior component of claim 11, wherein theinterior component is an interior trim piece of a vehicle.
 13. Theinterior component of claim 12, wherein the interior trim piece is aportion of an instrument panel of the vehicle.
 14. The interiorcomponent of claim 13, wherein outer skin layer is formed from leatherand the intermediary layer is foam and the substrate layer is formedfrom plastic.